Kelvion KBloc User manual
Operating Instructions - Vers 2.2 01.2016
K°Bloc – Fully welded plate heat exchangers
K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016
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WE ARE KELVION – THE NEW HEAT
EXCHANGER BRAND
In the future, GEA Heat Exchangers products will be sold under a new brand
name: Kelvion. However, the familiar performance and quality will remain
constants. The name of Kelvion is indeed new, but we are continuing a
successful business as global experts for plate heat exchangers. We wish to
enjoy your full confidence in all we do.
You will still be able to recognize us. We will continue to develop our
products, manufacture them with the utmost precision and sell them across
the globe. We remain the suppliers of one of the world's largest heat
exchanger product portfolios: Plate heat exchangers, shell-and-tube heat
exchangers, finned tube heat exchangers, cooling tower systems in modular
form, and refrigeration plate heat exchangers for multiple fields of applica-
tion.
These operating instructions are your personal guide explaining design,
function, installation, operation, maintenance, troubleshooting, transport and
repairs of our Plate heat exchangers in an easy-to-understand and clear
manner. They, in particular, aim to avoid possible hazards or damage right
from the beginning. This is why all employees working with the Plate heat
exchangers (PHE) should have access to these operating instructions at any
time.
If any questions remain unanswered, your Kelvion Sales Office or the
Central Service Dept. will be glad to help you.
Additional technical information is available for specific applications.
Visit our website:
www.kelvion.com
Here you find your competent Sales Office.
Responsible for the content:
Kelvion PHE GmbH
Karl-Schiller-Str. 1-3
D-31157 Sarstedt
Germany
Content
K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016 3
Content
1 PRODUCT INFORMATION ....................................................................... 6
1.1 TECHNICAL DATA........................................................................ 6
1.2 NAME PLATE ................................................................................ 6
1.3 TECHNICAL DOCUMENTATION.................................................. 7
2 USER INFORMATION............................................................................... 8
2.1 ABOUT THESE OPERATING INSTRUCTIONS ...........................8
2.2 VALIDITY....................................................................................... 9
2.3 DRAWINGS AND FIGURES ......................................................... 9
2.4 EMPHASIZED TEXT SECTIONS.................................................. 9
2.4.1 SAFETY NOTE.......................................................... 10
2.4.2 SAFETY INSTRUCTION ........................................... 10
2.4.3 WARNINGS............................................................... 11
2.4.4 PROCEDURE INSTRUCTION .................................. 12
2.4.5 SEQUENCE OF ACTIONS ....................................... 12
2.4.6 TIP............................................................................. 13
3 OVERVIEW AND DESCRIPTION ........................................................... 14
3.1 INTENDED USE .......................................................................... 14
3.2 FUNCTIONAL DESCRIPTION .................................................... 15
3.3 BASIC DESIGN ........................................................................... 16
3.4 PANEL GASKETS ....................................................................... 17
4 IMPORTANT SAFETY INFORMATION .................................................. 18
4.1 OPERATIONAL SAFETY ............................................................ 18
4.2 SAFETY INFORMATION............................................................. 19
4.2.1 INFORMATION ON TRANSPORTATION AND
SETTING UP ............................................................. 19
4.2.2 OPERATIONAL INFORMATION............................... 20
4.2.3 MAINTENANCE INFORMATION .............................. 20
4.2.4 DISMOUNTING INFORMATION............................... 21
4.3 OBLIGATIONS OF UNIT OPERATING COMPANY.................... 22
4.3.1 ENSURING SAFE OPERATION ............................... 22
4.3.2 TRAINING OF PERSONNEL .................................... 22
4.4 PERSONNEL QUALIFICATION .................................................. 23
4.5 PERSONAL PROTECTIVE EQUIPMENT................................... 23
4.6 ADDITIONAL PROTECTIVE EQUIPMENT................................. 24
4.7 RESIDUAL HAZARDS ON THE K°BLOC ................................... 24
4.8 NOTES / DECALS ON THE K°BLOC.......................................... 26
K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016
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5 SETTING UP AND CONNECTING THE K°BLOC .................................. 28
5.1 INSPECTING THE EQUIPMENT UPON DELIVERY .................. 28
5.1.1 TRANSPORT VARIANTS .........................................28
5.1.2 TRANSPORT PARTICULARITIES............................ 29
5.2 SPACE REQUIREMENT AT THE PLACE OF INSTALLATION .. 29
5.3 REMOVING AND DISPOSING OF TRANSPORT
PACKAGING................................................................................ 30
5.4 TRANSPORTING THE K°BLOC TO THE PLACE OF
INSTALLATION AND SETTING IT UP ........................................ 31
5.4.1 TRANSPORTING AND SETTING UP A K°BLOC
DELIVERED IN UPRIGHT POSITION ...................... 31
5.4.2 TRANSPORTING AND SETTING UP A K°BLOC
DELIVERED IN HORIZONTAL POSITION ............... 36
5.5 CONNECTING THE K°BLOC ...................................................... 51
5.5.1 OPTIONAL SAFETY ACCESSORIES ...................... 51
5.5.2 INSTALLING PIPING ................................................ 52
6 COMMISSIONING AND DECOMMISSIONING, OPERATION ............... 55
6.1 COMMISSIONING ....................................................................... 55
6.1.1 PRE-CONDITIONS ................................................... 56
6.1.2 COMMISSIONING..................................................... 56
6.2 OPERATION................................................................................ 60
6.3 DECOMMISSIONING .................................................................. 61
6.3.1 SHORT-TERM PUTTING OUT OF OPERATION ..... 61
6.3.2 DECOMMISSIONING - MAINTENANCE .................. 63
6.3.3 LONG-TERM PUTTING OUT OF OPERATION ....... 64
6.4 STORAGE ................................................................................... 65
6.5 DISPOSAL ................................................................................... 65
7 MAINTENANCE....................................................................................... 66
7.1 OPENING THE K°BLOC ............................................................. 67
7.1.1 PREPARATIONS ...................................................... 67
7.1.2 DISMOUNTING THE PANEL .................................... 69
7.2 REPLACING THE GASKETS...................................................... 76
7.3 REMOVING THE BAFFLE PLATE BRACKET ............................77
7.4 CLOSING THE K°BLOC .............................................................. 78
7.4.1 INSTALLING A SINGLE PANEL ............................... 79
7.4.2 TIGHTENING THE PANEL .......................................82
7.5 LEAKAGE TEST .......................................................................... 93
7.6 OUTSIDE CLEANING.................................................................. 94
7.7 CIP CLEANING ........................................................................... 95
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7.8 CLEANING BY REVERSE FLUSHING ....................................... 96
7.9 CLEANING THE PLATE PACK WITH THE K°BLOC
OPENED...................................................................................... 96
7.9.1 CLEANING PLATES WITH A CHEVRON
PATTERN.................................................................. 96
7.9.2 CLEANING PLATES WITH "DOUBLE DIMPLE"
PATTERN.................................................................. 98
8 TROUBLESHOOTING............................................................................. 99
8.1 INSUFFICIENT PERFORMANCE ............................................... 99
8.2 LEAKS ....................................................................................... 100
9 TECHNICAL TERMS............................................................................. 102
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